Raypak 0066B, 0180B, 0042B manual START-UPPROCEDURES Lighting the Boiler, For Standing Pilot Models

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START-UPPROCEDURES

Lighting the Boiler

Safe-lightingandotherperformancecriteriaweremet with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in the latest edition of the ANSI-Z21.13 Standard.

CAUTION: Propane gas is heavier than air and sinks to the ground. Exercise extreme care in lighting boiler in confined areas.

For Standing Pilot Models

WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A.This boiler has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly.

B.BEFORE LIGHTING Smell all around the boiler area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electric switch;

Do not use any phone in your building.

Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

If you cannot reach your gas supplier, call the fire department.

C.Use only your hand to push in, move or turn the gas control knob or lever. Never use tools. If the knob or lever will not push in, move or turn by hand, don't try to repair it. Call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D.Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water.

Filling the System

Flush system before putting into operation to ensure that foreign material does not damage pump seals.

Fill system with water. Purge all air from the system using purge valve sequence. After system is purged of air, lower system pressure. Open valves for normal system operation, fill system through feed pressure regulator to minimum 12 PSI. Manually open air vent on the compression tank until water appears, then close vent.

On multiple-zone systems, purge each zone sepa- rately. Isolate the other zones while one zone is being purged of air.

Checking the Circulator

Before lighting the boiler and after system is filled, make sure that circulator is operating properly. Manual gas valve should be off. By adjusting the wall thermo- stat to the maximum setting, circulator should run immediately and allow water to flow through the boiler and the entire system.

NOTE: Circulator motor supplied with the boiler does not require lubrication.

CAUTION: In case of a prolonged power failure during freezing weather conditions, boiler and piping system must be drained completely to avoid possible damage to the heating system.

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Contents FOR YOUR SAFETY RaythermTM Type H RESIDENTIAL BOILERS Models0042B, 0066B,0090B 0135B, 0180B INSTALLATION AND OPERATING INSTRUCTIONSContents GENERAL SPECIFICATIONSINSTALLATION PROCEDURES SERVICING PROCEDURESGENERAL SPECIFICATIONS RECEIVING EQUIPMENT3. INSTALLATION PROCEDURES CODE REQUIREMENTSMOUNTING BASE CLEARANCEREQUIREMENTSVENTING CONNECTIONS COMMON VENTS VENT DAMPER INSTALLATION Hole in Vent Damper Blade Closed Position VENT DAMPER OPERATION FLAIR DAMPERVENT DAMPER WIRING DIAGRAM GAS SUPPLY CONNECTIONS GASPRESSUREWATER CONNECTIONS & SYSTEM PIPING PIPING DIAGRAMS SINGLE-ZONEPIPINGZONE HEATING WITH INDIRECT DOMESTIC HOT WATER SUPPLYZONE VALVES HEATINGUNITS AIR SCOOP DIAPHRAGM EXPANSION FEED TANK VALVEMULTIPLE ZONES WITH CIRCULATORS MULTIPLE ZONES WITH ZONE VALVESELECTRICAL WIRING WIRING DIAGRAM KEYWIRING DIAGRAMS Page Page WIRING DIAGRAM Single-ZoneTaco Valve WIRING DIAGRAM Dual-ZoneTaco ValveWIRING DIAGRAM Dual-ZoneHoneywell Valve Fig. # 2228eWIRING DIAGRAM System with 3 Zone Pumps WIRING DIAGRAM: Power Vent System w/ Zone ValveFig. #2232e Fig. #2233e Fig. #2234eWIRING DIAGRAM Primary/Secondary Pumping System Honeywell Zone ValveFig. #2223.2e Note Low water cut-offLWCO and system switch supplied by others SERVICING PROCEDURES GENERAL LOCATION OF CONTROLSSTART-UPPROCEDURES Lighting the Boiler For Standing Pilot ModelsFilling the System Checking the CirculatorHONEYWELL PILOT ROBERTSHAW PILOTTO TURN OFF GAS TO THE BOILER Models FOR AUTOMATIC IGNITION MODELSSHUT-DOWNPROCEDURE TO TURN OFF GAS TO BOILER3.For Honeywell valve For Robertshaw valveFOR AUTOMATIC IGNITION SYSTEMS INSPECTION PROCEDURES BURNERS SAFE SHUT-DOWNTESTS LIMIT ACTIONFLAME FAILURE INSPECTIONSCHEDULERAYPAK TUBE CLEANING KIT REPAIRPROCEDURESHEAT EXCHANGER RE-ASSEMBLY TROUBLESHOOTING GUIDE PROBLEMSOLUTIONS IMPORTANT NOTICE10Defective ignition module or defective gas valve ADJUSTMENT/REPLACEMENTOF COMPONENTS DANGER - SHOCK HAZARDREPLACEMENT PARTS LIST RAYPAK, INC 2151 Eastman Avenue Oxnard, CAPage Page Page LIMITED PARTS WARRANTY HEAT EXCHANGER WARRANTYADDITIONAL WARRANTY EXCLUSIONS PARTS REPLACEMENT
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